Low water activity filling

ABSTRACT

A flavored filling having a low water activity. The filling includes a flavoring agent, an edible oil, and humectant. The edible oil can include a high and a low melting temperature oil. The high melting point oil, when used, can act as a crystal seeding agent during the formation of the filling.

The present invention is a divisional of U.S. patent application Ser.No. 09/748,768 filed Dec. 27, 2000, now U.S. Pat. No. 6,528,104.

The subject invention relates generally to an improved filling, and moreparticularly to a low water activity fruit filling for use in a foodproduct.

BACKGROUND OF THE INVENTION

Filled food products, such as pies, cakes, waffles, donuts, candies,cereal bars, and the like are commonly filled with various types offlavored fillings such as fruit fillings, marshmallow fillings, peanutputter fillings, vegetable fillings, and the like. These food productsare commonly prepackaged for later use by the consumer. The process forfilling the food product, packaging the food product and impartingadequate shelf-life to the food product has presented numerous problemsrelating to food product quality. One such problem is the introductionand retention of high flavoring of the filling. To provide highflavoring and other qualities, such as pleasing mouth feel, the flavoredfilling traditionally needed to be formulated with a high water content.While the high water content provides pleasing qualities to theconsumer, it also causes stability problems for the filled food product.One such problem is the migration of water from the filling materialinto the casing material of the filled food product. The area of surfacecontact between the two materials provides a potential for instabilitybetween the two materials leading to chemical reactions that can causethe degradation of the food product. Water migration also can cause thecasing material to become soggy and the filling material to lose itsflavoring, each of which reduces the overall satisfaction of theconsumer.

One method for preventing the degradation of the filled food product dueto water migration is disclosed in U.S. Pat. No. 4,623,542. The '542patent discloses the use of a dough and a roll-in shortening laminatedpad to prevent the migration of water from the filling material to thecasing material. Additionally, the filling material is formulated to actas a moisture sink while cooking the filled food product in preparationfor storage.

Another method for preventing the migration of water has been simply toreduce the water content of both the filling material and the casingmaterial and/or to maintain the water activity of the filling to be lessthan or equal to the casing material. The lower water content of thefilling and/or casing material reduces the amount of free water in thefood product thereby reducing the amount of water that is capable ofmigrating between the filling material and the casing material. However,the lack of water in the filled food product also reduces the overallflavor and mouth-feel and eating quality resulting in reduced consumersatisfaction. The following is an example of typical water activitiesfor a variety of high solids fillings and confections:

Filling Water Activity Crème Cookie Filling 0.535 Peanut Butter PecanCookie Filling 0.552 Fudge Cookie Filling 0.421 Mint Confection Filling0.661 Caramel Crème Filling 0.538 Gelatin Gummis 0.666 Caramels 0.567Circus Peanuts 0.641 Cereal Bar Fruit Filling 0.660 Strawberry FruitFilling 0.805

Typical fruit fillings have water activities of 0.60 or greater. Fruitfillings that have lower water activities generally have a rubbery,grainy texture with poor flavor release and eating characteristics. Thetypical method for achieving a lower water activity primarily relies onincreasing solids at the expense of moisture. Lowering the wateractivity in this manner frequently results in a fruit filling with poorflavor release, poor textural and poor rheological attributes. Inaddition, low water activity fruit fillings typically have excessiveviscosity development during the manufacture of the fruit filling thusmaking it difficult to incorporate dry ingredients. Often, additionalmoisture must be added to the fruit filling to provide a fluid matrix inwhich the dry ingredients can be either dispersed or dissolved. Thisrequires that the moisture be removed at some later step (i.e., usingvacuum and heat) if the final low water activity is to be achieved. Therheological characteristics of a low water activity fruit filling alsomakes it more difficult to pump and/or extrude the fruit filling forpackaging and/or insertion in a final food product.

The maintaining of the water activity of the filling so as to not begreater than the food casing material reduces the tendency of the waterin the filling to migrate to the case material. However, many types offillings, especially fruit fillings, need to have a high water activityto obtain the desired overall flavor and mouth feel associated with thefruit filling. Such high water activities of the filling resulted inpoor quality and unstable food casings when the water activity of thefood casing is raised so as to be equal or greater than the wateractivity of the filling. As a result the shelf life and quality of thefilling food product was reduced.

Therefore, it would be desirable to develop a filled food product havinga filling with a low water activity and which filling has desirableorganoleptic characteristics and which can be manipulated both inmanufacture and during end use.

SUMMARY OF THE INVENTION

The invention relates to a low water activity food product and moreparticularly to a low water activity filling for use as a filling for afood product. The filling can be a fruit filling or a filling thatincludes substantially little or no fruit. The filling is formulated tohave a high solids content and a low water activity. The solids contentof the filling typically constitutes a majority of the filling. Thewater activity of the filling is generally selected so as to reduce theamount of moisture transfer to a food casing. The filling is formulatedto maintain the sweetness, flavor and other desired organolepticcharacteristics while maintaining a low water activity. The viscosity ofthe filling is such that the filling can be pumped, extruded and/orotherwise deposited on and/or in a food casing in a manner similar tofillings with higher water activities.

In one aspect of the present invention, the water activity of thefilling is sufficiently low to reduce or substantially prevent moisturemigration from the filling to a food casing. In one embodiment, thewater activity (A_(w)) of the filling is less than or equal to the wateractivity of the finished food casing. In one aspect of this embodiment,the water activity of the filling is less than the water activity of afood casing generally made from a dough or butter comprised at leastpartially of flour. Typically the flour includes, but is not limited to,all-purpose flour, hard wheat flour, soft wheat flour, whole wheatflour, corn flour, oat flour, rice flour, and/or barley flour. Foodproducts that have food casing made from flour include, but are notlimited to, pies, cakes, cup cakes, strudels, cobblers, bagels, breads,crepes, toast, tarts, pancakes, waffles, muffins, cookies, crackers,pastries, donuts, crusts, granola bars, cereal bars, biscuits,turnovers, pizzas, pot pie, pasta, burritos, and calzones. In onespecific aspect of this embodiment, the water activity of the fillingwhen used in food casings including flour is less than about 0.8. Inanother specific aspect of this embodiment, the water activity of thefilling when used in food casings including flour is less than about0.7. In still another specific aspect of this embodiment, the wateractivity of the filling when used in food casings including flour isless than about 0.65. In yet another specific aspect of this embodiment,the water activity of the filling when used in food casings includingflour is less than about 0.6. In still yet another specific aspect ofthis embodiment, the water activity of the filling when used in foodcasings including flour is less than about 0.5. In a further specificaspect of this embodiment, the water activity of the filling when usedin food casings including flour is less than about 0.4. In still afurther specific aspect of this embodiment, the water activity of thefilling when used in food casing made of flour is less than about 0.35.In yet a further specific aspect of this embodiment, the water activityof the filling when used in food casing made of flour is less than about0.3. In still yet a further specific aspect of this embodiment, thewater activity of the filling when used in food casing made of flour isless than about 0.25. In another specific aspect of this embodiment, thewater activity of the filling when used in food casing made of flour isless than about 0.2. In another embodiment, the filling has a wateractivity that is sufficiently low so as to increase the shelf life ofthe food product.

Fillings are commonly inserted into various types of candies andchocolates. Fillings such as fruit fillings, caramel fillings, creamfillings, marshmallow fillings and the like, are commonly encased in acandy or chocolate coating. In one specific aspect of this embodiment,the water activity of the filling when used in candies and chocolates isless than about 0.95. In another specific aspect of this embodiment, thewater activity of the filling when used in candies and chocolates isless than about 0.85. In still another specific aspect of thisembodiment, the water activity of the filling when used in candies andchocolates is less than about 0.8. In yet another specific aspect ofthis embodiment, the water activity of the filling when used in candiesand chocolates is less than about 0.7. In still yet another specificaspect of this embodiment, the water activity of the filling when usedin candies and chocolates is less than about 0.6. In a further specificaspect of this embodiment, the water activity of the filling when usedin candies and chocolates is less than about 0.5. In yet a furtherspecific aspect of this embodiment, the water activity of the fillingwhen used in candies and chocolates is less than about 0.4. In still afurther specific aspect of this embodiment, the water activity of thefilling when used in candies and chocolates is less than about 0.35. Inyet a further specific aspect of this embodiment, the water activity ofthe filling when used in candies and chocolates is less than about 0.3.In still yet a further specific aspect of this embodiment, the wateractivity of the filling when used in candies and chocolates is less thanabout 0.25. In another specific aspect of this embodiment, the wateractivity of the filling when used in candies and chocolates is less thanabout 0.2.

In another aspect of the invention, the filling includes a combinationof edible oil and humectant to achieve the low water activity of thefilling. The edible oil and the humectant are, in one sense, used as apartial or full substitute for water in the filling, thus enabling thefilling to be formulated with a low water activity. The edible oil andhumectant also function to fluidize and plasticize the filling therebyfacilitating in dispersing other components of the filling when added tothe filling during the manufacturing of the filling. The edible oil andhumectant further facilitate in the filling being easily processed (i.epumped, stirred, mixed, extruded, etc.) during the manufacturing of thefilling. The edible oil and humectant still further facilitate in thefilling being easily pumped, extruded or otherwise deposited on and/orin a food casing or directed into packaging for later use. The oil alsofunctions as a high temperature stabilizing agent for the filling whenthe final filling is exposed to temperatures above ambient temperature.The humectant also functions to bind the components of the fillingtogether. In one embodiment, the humectant includes, but is not limitedto, glycerine, 1,3-butyl glycol, mannitol, sorbitol, fructose, and/orpropylene glycol. In one aspect of this embodiment, the humectantincludes glycerin. In another aspect of this embodiment, the humectantincludes propylene glycol. In another embodiment, the humectantconstitutes less than a majority weight percent of the final filling. Inone aspect of this embodiment, the humectant constitutes up to about 40weight percent of the final filling. In another aspect of thisembodiment, the humectant constitutes at least about 0.1 weight percentof the final filling. In yet another aspect of this embodiment, thehumectant constitutes about 0.1-40 weight percent of the final filling.In still another aspect of this embodiment, the humectant constitutesabout 0.1-30 weight percent of the final filling. In still yet anotheraspect of this embodiment, the humectant constitutes about 1-30 weightpercent of the final filling. In a further aspect of this embodiment,the humectant constitutes about 10-25 weight percent of the finalfilling. In yet another embodiment, the edible oil includes natural,hydrogenated, and/or partially hydrogenated oils. The source of theedible oil includes, but is not limited to, soybean, cottonseed, canola,rapeseed, peanut, safflower, sunflower, coconut, palm, palm kernel,olive, butterfat, cocoa butter, tallow, lard, and/or corn. In still yetanother embodiment, the edible oil constitutes up to 80 weight percentof the final filling. In one aspect of this embodiment, the edible oilconstitutes up to about 60 weight percent of the final filling. Inanother aspect of this embodiment, the edible oil constitutes up toabout 50 weight percent of the final filling. In yet another aspect ofthis embodiment, the edible oil constitutes at least about 0.01 weightpercent of the final filling. In still another aspect of thisembodiment, the edible oil constitutes about 0.01-50 weight percent ofthe final filling. In still yet another aspect of this embodiment, theedible oil constitutes up to about 40 weight percent of the finalfilling. In a further aspect of this embodiment, the edible oilconstitutes about 0.01-30 weight percent of the final filling. In yet afurther aspect of this embodiment, the edible oil constitutes about 5-30weight percent of the final filling. In still yet a further aspect ofthis embodiment, the edible oil constitutes about 10-25 weight percentof the final filling.

In still another aspect of the invention, the filling includes acombination of at least two edible oils wherein at least one edible oilis a low melting point oil and at least one edible oil is a high meltingpoint oil. The low melting point oil and high melting point oil aremanipulated in the filling to cause the filling to have a substantiallysmooth texture and flowable composition, and to maintain suchcharacteristics even when the filling is heated. The high melting pointoil is used as a crystal seeding substance to cause crystals to grow asthe filling is cooled during the manufacturing of the filling and can beused also to adjust the melting point and setting time of the filling.The high melting point oil also functions as a stabilizing agent to thefinal filling when the final filling is exposed to higher temperatures.The high melting point oil can constitute one or more edible oils andcan include a composition of triglycerides, diglycerides, ormonoglycerides or any mixture thereof. The low melting point oil canalso constitute one or more edible oils. Each high melting point oil hasan average melting point temperature that is greater than the averagemelting point of the low melting point oil. In one embodiment, theaverage melting point temperature of the high melting point oil is atleast about 5° F. above the average melting point temperature of the lowmelting point oil. In one aspect of this embodiment, the average meltingpoint temperature of the high melting point oil is at least about 10° F.above the average melting point temperature of the low melting pointoil. In another aspect of this embodiment, the average melting pointtemperature of the high melting point oil is at least about 20° F. abovethe average melting point temperature of the low melting point oil. Instill another aspect of this embodiment, the average melting pointtemperature of the high melting point oil is at least about 30° F. abovethe average melting point temperature of the low melting point oil. Instill yet another aspect of this embodiment, the average melting pointtemperature of the high melting point oil is at least about 40° F. abovethe average melting point temperature of the low melting point oil. Instill another embodiment, the average melting point temperature of thehigh melting point oil greater than about 110° F. In one aspect of thisembodiment, the average melting point temperature of the high meltingpoint oil is greater than about 140° F. In another aspect of thisembodiment, the average melting point temperature of the high meltingpoint oil is about 130-200° F. In still another aspect of thisembodiment, the average melting point temperature of the high meltingpoint oil is about 133-180° F. In still yet another aspect of thisembodiment, the average melting point temperature of the high meltingpoint oil is about 133-160° F. In yet another aspect of this embodiment,the high melting point oil includes, but is not limited to, a soybeanbased edible oil sold under the trade name Dritex S Flakes by AC Humko.In yet another embodiment, the average melting point temperature of thelow melting point oil is up to about 120° F. In one aspect of thisembodiment, the average melting point temperature of the low meltingpoint oil is about 60-110° F. In another aspect of this embodiment, thelow melting point oil includes, but is not limited to, a soybean basededible oil sold under the trade name PS 12 by AC Humko. In still yetanother embodiment, the weight percentage of the low melting point oilin the final filling is greater than the weight percentage of the highmelting point oil in the final filling. In one aspect of thisembodiment, the weight percentage of the low melting point oil is atleast two times greater than the weight percentage of the high meltingpoint oil in the final filling. In another aspect of this embodiment,the weight percentage of the low melting point oil is at least threetimes greater than the weight percentage of the high melting point oilin the final filling. In still another aspect of this embodiment, theweight percentage of the low melting point oil is at least five timesgreater than the weight percentage of the high melting point oil in thefinal filling. In yet another aspect of this embodiment, the weightpercentage of the low melting point oil is at least ten times greaterthan the weight percentage of the high melting point oil in the finalfilling. Instill another embodiment, the high melting point oil is up toabout 30 weight percent of the final filling. In one aspect of thisembodiment, the high melting point oil is about 0.01-30 weight percentof the final filling. In another aspect of this embodiment, the highmelting point oil is about 0.01-20 weight percent of the final filling.In yet another aspect of this embodiment, the high melting point oil isabout 0.01-10 weight percent of the final filling. In still anotheraspect of this embodiment, the high melting point oil is about 0.05-5weight percent of the final filling. In still yet another aspect of thisembodiment, the high melting point oil is about 0.05-2 weight percent ofthe final filling. In a further aspect of this embodiment, the highmelting point oil is about 0.5-1.5 weight percent of the final filling.In still yet another embodiment, the low melting point oil is up toabout 60 weight percent of the final filling. In one aspect of thisembodiment, the low melting point oil is up to about 50 weight percentof the final filling. In another aspect of this embodiment, the lowmelting point oil is about 5-25 weight percent of the final filling. Instill another aspect of this embodiment, the low melting point oil isabout 10-25 weight percent of the final filling. In still yet anotheraspect of this embodiment, the low melting point oil is about 15-25weight percent of the final filling. In a further aspect of thisembodiment, the low melting point oil is about 15-22 weight percent ofthe final filling.

In still another aspect of the invention, the filling is a fruit fillingthat includes natural and/or artificial fruit. Many types of fruitand/or combinations of fruit can be used in the filling. The fruitsource includes, but is not limited to, fruit puree, fruit pureeconcentrate, fruit juice, fruit juice concentrate, fruit pieces, fruitconcentrate, dried fruit, dehydrated fruit, fruit flakes, fruit powder,fruit extract, fruit flavored oils, artificial fruit, artificial fruitconcentrate, and mixtures thereof. Examples of a few of the manyspecific fruits which can be utilized in the filling include, but arenot limited to, berries of all types, currants, apricots, peaches,nectarines, plums, cherries, apples, pears, oranges, grapefruits,lemons, limes, tangerines, mandarins, tangelos, bananas, pineapples,grapes, tomatoes, rhubarbs, prunes, figs, pomegranates, passion fruit,guava, kiwi, kumquat, mangos, avocados, all types of melons, and/orpapaya. In one embodiment, dried fruit flakes are included in thefilling. Fruit flakes are a desirable vehicle when adding fruit to afilling. Fruit flakes contain little water, thus do not cause the wateractivity of the final filling to substantially increase. In one aspectof this embodiment, the fruit flakes are the primary source of fruit inthe filling. In another aspect of this embodiment, fruit flakes arecombined with one or more fruit sources to provide the fruit content ofthe filling. In another embodiment, the fruit content of the finalfilling constitutes up to a majority of the filling. In one aspect ofthis embodiment, the fruit content of the final filling constitutes upto about 40 weight percent of the filling. In another aspect of thisembodiment, the fruit content of the final filling constitutes at leastabout 0.05 weight percent of the filling. In still another aspect ofthis embodiment, the fruit content of the final filling constitutes upto about 30 weight percent of the filling. In yet another aspect of thisembodiment, the fruit content of the final filling constitutes about0.1-30 weight percent of the filling. In a further aspect of thisembodiment, the fruit content of the final filling constitutes about1-25 weight percent of the filling. In still a further aspect of thisembodiment, the fruit content of the final filling constitutes about5-20 weight percent of the filling. In yet a further aspect of thisembodiment, the fruit content of the final filling constitutes about10-20 weight percent of the filling. In still yet a further aspect ofthis embodiment, the fruit content of the final filling constitutesabout 12-20 weight percent of the filling.

In yet another aspect of this invention, the filling is a non-fruitfilling. Such fillings include, but are not limited to, chocolatefillings, marshmallow fillings, vanilla fillings, nut fillings, peanutbutter fillings, caramel fillings, cream fillings, and the like. In oneembodiment, the flavoring component of the non-fruit filling constitutesup to about 30 weight percent of the filling. In one aspect of thisembodiment, the flavoring component constitutes about 0.01-25 weightpercent of the filling. In another aspect of this embodiment, theflavoring component constitutes about 0.1-20 weight percent of thefilling. In yet another aspect of this embodiment, the flavoringcomponent constitutes about 0.1-10 weight percent of the filling. Instill another aspect of this embodiment, the flavoring componentconstitutes about 0.1-5 weight percent of the filling.

In still yet another aspect of the invention, the filling includes asweetener. The sweetener enhances the flavor of the final filling. Thesweetener also modifies the fluidity of the filling during manufactureof the filling and after the final filling is formed. The sweetener caninclude, but is not limited to, sucrose, dextrose, fructose, lactose,malt syrup, malt syrup solids, rice syrup, rice syrup solids, invertsugar, refiners syrup, corn syrup, corn syrup solids, maltose, highfructose corn syrup, fructose syrup, honey, molasses, grain syrups,agave, and/or artificial sweeteners (aspartame, sucralose, saccharin).In one embodiment, the sweetener includes syrup, honey, and/or molasses.The syrup, honey, and/or molasses add sweetness to the filling, add somewater to the filling, and provide fluidity to the filling to enableother components of the filling to be mixed together during manufactureof the filling and/or facilitate in the pumping and/or extruding of thefinal filling into packaging and/or in the final food product. Inanother embodiment, the sweetener includes dried and/or powderedsweetener. The powdered and/or dried sweetener adds sweetness to thefinal filling; however, such sweetener adds little or no water to thefilling, thus does not cause an increase in the water activity of thefinal filling. In still another embodiment, non-powdered and/ornon-dried sweetener and powdered and/or dried sweetener are added to thefinal filling. In yet another embodiment, the sweetener constitutes upto a majority of the final filling. In one aspect of this embodiment,the sweetener constitutes up to about 80 weight percent of the finalfilling. In another aspect of this embodiment, the sweetener constitutesat least about one weight percent of the final filling. In yet anotheraspect of this embodiment, the sweetener constitutes up to about 50weight percent of the final filling. In still another aspect of thisembodiment, the sweetener constitutes about 10-50 weight percent of thefinal filling. In still yet another aspect of this embodiment, thesweetener constitutes about 30-50 weight percent of the final filling.In still a further aspect of this embodiment, the sweetener constitutesabout 30-45 weight percent of the final filling.

In a further aspect of the invention, the filling includes a starch. Thestarch is added as a thickening agent, a body forming agent to thefilling, a stabilizer for the filling, and/or organolepticcharacteristic enhancer of the final filling. The starch content of thefilling can be adjusted to dictate the consistency and texture of thefilling. As with the addition of the sweetener to the filling, theaddition of starch to the filling modifies the processability of thefilling without the need to add significant amounts of water to thefilling. The starch can include, but is not limited to, flours, naturalor modified starches, corn, waxy corn, rice, wheat, tapioca, potato,arrowroot, maize, and/or oat. In one embodiment, an instant granularmodified starch that is hydrateable by water into a highly viscose freestanding mass is included in the filling. One type of instant granularmodified starch that can be used in the filling is a modified cornstarch sold under the trademark MIRA-THIK by A. E. Staley ManufacturingCompany. In another embodiment, an instant granular starch hydrateableby water to form a resilient, colloidal gel structure is included in thefilling. One type of instant granular starch that can be used in thefilling is a natural instant granular corn starch sold under thetrademark MIRA-GEL by A. E. Staley Manufacturing Company. In stillanother embodiment, the starch content of the final filling is up toabout 15 weight percent. In one aspect of this embodiment, the starchcontent is about 0.01-15 weight percent of the final filling. In anotheraspect of this embodiment, the starch content is about 0.1-5 weightpercent of the final filling. In yet another aspect of this embodiment,the starch content is about 0.1-4 weight percent of the final filling.

In still a further aspect of the invention, the filling includes anemulsifier. The emulsifier modifies and stabilizes the crystallizationof the edible oil in the filling when the filling is cooled.Specifically, the emulsifier delays the formation of crystals and/orhelps stabilize the formed crystals during the cooling of the filling.The emulsifier includes, but is not limited to, lecithin, glycerolesters, diacetyl tartaric acids, esters of monoglycerides, mono anddi-glycerides, polyglycerol esters, polysorbate, propylene glycolesters, rice extract esters, sodium stearoyl-2-lactylate, sorbitanesters, sugar esters, and/or acetylated monoglycerides. In oneembodiment, the lecithin content of the final filling is up to about 10weight percent. In one aspect of this embodiment, the lecithinconstitutes up to about 5 weight percent of the final filling. Inanother aspect of this embodiment, the lecithin constitutes about 0.01-5weight percent of the final filling. In still another aspect of thisembodiment, the lecithin constitutes about 0.05-2 weight percent of thefinal filling. In yet another aspect of this embodiment, the lecithinconstitutes about 0.05-1 weight percent of the final filling. In stillyet another aspect of this embodiment, the lecithin constitutes about0.1-1 weight percent of the final filling.

In still yet a further aspect of the invention, the filling includes oneor more additional components to alter the flavor, color, shelf life,and/or organoleptic characteristics of the filling. The additionalcomponents include, but are not limited to, natural and/or artificialflavorings, acidulants, coloring agents, stabilizers, salt,antimicrobial preservatives, vitamins, minerals, and/or antioxidantpreservatives. One or more of these additional components are used toincrease the shelf life of the filling, improve the nutritional value ofthe filling, improve the taste of the filling, alter and/or improve theappearance of the filling, and/or improve one or more organolepticcharacteristics of the filling. When natural and/or artificialflavorings are included in the filling, the natural and/or artificialflavorings include artificial fruit, artificial fruit concentrate,natural fruit, natural fruit concentrate, artificial vegetable,artificial vegetable concentrate, natural vegetable, natural vegetableconcentrate, fruit extract, vegetable extract, cocoa, caramel, caramelpowder, maple syrup, spices, herbs, and/or flavored oils. As can beappreciated, other natural and/or artificial flavorings can bealternatively or additionally used in the filling. When natural fruitand/or natural fruit concentrate are used as a flavoring agent, theweight percentage of the natural fruit and/or natural fruit concentrateis included in the weight percentage of the fruit used in the filling.Similarly, when natural vegetable and/or natural vegetable concentrateare used as a flavoring agent, the weight percentage of the naturalvegetable and/or natural vegetable concentrate is included in the weightpercentage of the vegetable used in the filling. In one embodiment, thenatural and/or artificial flavoring, when added to the filling,constitutes at least about 0.01 weight percent of the final filling. Inone aspect of this embodiment, the natural and/or artificial flavoringconstitutes up to about 30 weight percent of the final filling. Inanother aspect of this embodiment, the natural and/or artificialflavoring constitutes up to about 20 weight percent of the finalfilling. In yet another aspect of this embodiment, the natural and/orartificial flavoring constitutes about 0.01-20 weight percent of thefinal filling. In still another aspect of this embodiment, the naturaland/or artificial flavoring constitutes about 0.01-20 weight percent ofthe final filling. In still yet another aspect of this embodiment, thenatural and/or artificial flavoring constitutes about 0.01-5 weightpercent of the final filling. In a further aspect of this embodiment,the natural and/or artificial flavoring constitutes about 0.1-2 weightpercent of the final filling. When one or more acidulants are includedin the filling, the acidulant generally includes citric acid, malicacid, tartaric acid, lactic acid, acetic acid, phosphoric acid, adipicacid, glucono delta lactone acid, fumaric acid, succinic acid, tannicacid, folic acid, ascorbic acid, and/or pantothenic acid. As can beappreciated other acidulants can be alternatively or additionally usedin the filling. In one embodiment, the acidulant, when added to thefilling, constitutes at least about 0.01 weight percent of the finalfilling. In one aspect of this embodiment, the acidulant constitutes upto about 10 weight percent of the final filling. In another aspect ofthis embodiment, the acidulant constitutes up to about 5 weight percentof the final filling. In yet another aspect of this embodiment, theacidulant constitutes about 0.01-5 weight percent of the final filling.In still another aspect of this embodiment, the acidulant constitutesabout 0.05-5 weight percent of the final filling. In still yet anotheraspect of this embodiment, the acidulant constitutes about 0.1-1.5weight percent of the final filling. In a further aspect of thisembodiment, the acidulant constitutes about 0.1-1 weight percent of thefinal filling. When one or more coloring agents are included in thefilling, coloring agents generally includes natural and/or artificialcoloring agents. The coloring agents include coal tar dyes, aluminumlake insoluble coal tar dyes, concentrated or dry forms of grape skinextracts, titanium oxide, grape concentrate, purple carrot concentrate,fruit extracts, fruit juice concentrates, vegetable extracts, vegetablejuice concentrates, beet, carmine, cochineal extracts, annatto, paprika,tumeric, beta carotene, purple potato, and/or radish. As can beappreciated other coloring agents can be alternatively or additionallyused in the filling. In one embodiment, the coloring agent, when addedto the filling, constitutes at least about 0.005 weight percent of thefinal filling. In one aspect of this embodiment, the coloring agentconstitutes up to about 5 weight percent of the final filling. Inanother aspect of this embodiment, the coloring agent constitutes up toabout 2 weight percent of the final filling. In yet another aspect ofthis embodiment, the coloring agent constitutes about 0.01-1 weightpercent of the final filling. Fillings made to water activity levels of0.7 or 0.6 and below are generally considered microbiologically stable.If the filling is in risk of being subjected to water, antimicrobialpreservatives can be added to control microbiological growth. When oneor more antimicrobial preservatives are included in the filling,antimicrobial preservatives generally include sodium benzoate, potassiumsorbate. As can be appreciated other antimicrobial preservatives can bealternatively or additionally used in the filling. In one embodiment,the antimicrobial preservative, when added to the filling, constitutesup to about 2 weight percent of the final filling. In one aspect of thisembodiment, the antimicrobial preservative constitutes up to about 0.5weight percent of the final filling. In another aspect of thisembodiment, the antimicrobial preservative constitutes at least about0.005 weight percent of the final filling. When one or more vitaminsand/or minerals are included in the filling, vitamins and/or mineralsgenerally include ascorbic acid, beta carotene, biotin, calciumpantothenate, choline, folic acid, niacin, vitamin A, vitamin B₁,vitamin B_(2,), vitamin B₆, vitamin B₁₂, vitamin D_(2,), vitamin D₃,niacinamide, vitamin E, vitamin K, boron, calcium, chromium, copper,iodine, iron, magnesium, molybdenum, nickel, potassium, selenium,vanadium, and/or zinc As can be appreciated other vitamins and mineralscan be alternatively or additionally used in the filling. In oneembodiment, the vitamin and/or mineral preservatives, when added to thefilling, constitute up to about 5 weight percent of the final filling.In one aspect of this embodiment, the vitamins and/or mineralsconstitute up to about 2 weight percent of the final filling. In anotheraspect of this embodiment, the vitamins and/or minerals constitute atleast about 0.1 weight percent of the final filling. When one or moresalts are included in the filling, salt generally includes potassiumchloride and/or calcium chloride. As can be appreciated, other salts canbe alternatively or additionally used in the filling. In one embodiment,the salt, when added to the filling, constitutes up to about 2 weightpercent of the final filling. In one aspect of this embodiment, the saltconstitutes up to about 1 weight percent of the final filling. Inanother aspect of this embodiment, the salt constitutes at least about0.05 weight percent of the final filling. When one or more stabilizersare included in the filling, the stabilizer generally includescellulose, cellulose gel, cellulose gum, pectin, seaweed, xanthan gum,carrageenan, an alginate, cellulosegums, modified starches, gelatinand/or maltodextrins. The cellulose, cellulose gel, cellulose gum, andxanthin gum are chosen from, but are not limited to, pectin, guar,locust bean, tara, gellan, alginate, tragacanth, karaya, Ghatti, agar,seaweed, gelatin, arabic, acacia, carrageenan, carboxmethylcellulose,and/or hydropropylmethocellulose gum. As can be appreciated, otherstabilizers can be alternatively or additionally used in the filling. Inone embodiment, the stabilizer, when added to the filling, constitutesup to about 2 weight percent of the final filling. In one aspect of thisembodiment, the stabilizer constitutes up to about 1 weight percent ofthe final filling. In another aspect of this embodiment, the stabilizerconstitutes at least about 0.01 weight percent of the final filling.When antioxidant preservatives are included in the filling, antioxidantpreservatives generally include BHA, BHT and/or TBHQ. As can beappreciated, other antioxidant preservatives can be alternatively oradditionally used in the filling. The antioxidant preservatives can beadded to increase shelf life of the filling. In one embodiment, theantioxidant preservative, when added to the filling, constitutes atleast about 0.001 weight percent of the final filling. In one aspect ofthis embodiment, the antioxidant preservative constitutes up to about 2weight percent of the final filling. In another aspect of thisembodiment, the antioxidant preservative constitutes up to about 0.01-1weight percent of the final filling. In still another aspect of thisembodiment, the antioxidant preservative constitutes up to about0.01-0.5 weight percent of the final filling.

In another aspect of the present invention, the water content of thefinal filling is sufficiently low so as to control the water activity ofthe final filling. In one embodiment of the invention, the water contentof the final filling is less than about 25 weight percent. In one aspectof this embodiment, the water content of the final filling is less thanabout 15 weight percent. In another aspect of this embodiment, the watercontent of the final filling is less than about 10 weight percent. Instill another aspect of this embodiment, the water content of the finalfilling is less than about 6 weight percent. In yet another aspect ofthis embodiment, the water content of the final filling is less thanabout 5.5 weight percent. In still yet another aspect of thisembodiment, the water content of the final filling is less than about 5weight percent.

In still another aspect of the invention, the filling is formed by anovel process to achieve the low water activity of the filling andmaintain the desired organoleptic characteristics of the filling thatare commonly associated with fillings having higher water activities.The novel process involves the controlling of the size and type of fatcrystals in the final filling. The size and type of fat crystals ismaintained so as to form a crystalline network or structure thatprevents settling of solids, thus maintaining a more homogeneousstructure, prevents oil separation, provides desirable consistency byreducing the granular texture and granular taste of the final filling.The size and type of fat crystals is maintained so that the filling canbe pumped, poured and/or extruded into packaging for later use, insertedinto a food casing and/or applied to the surface of a food product. Thenovel process also controls the temperature at which the final foodproduct is pumped, poured and/or extruded into packaging for later use,inserted into a food casing and/or applied to the surface of a foodproduct. By controlling the fat crystal size and type in the finalfilling and the temperature at which the final filling is packaged orapplied to another food product, a high quality filling is formed havinglow water activity and desired organoleptic characteristics. Whenmanufacturing the filling, the one or more edible oils used in thefilling are substantially fully melted. Typically, the temperature ofthe one or more oils is maintained at least about 5° F. above themelting point of the highest melting point edible oil included in thefilling. After the one or more edible oils are melted, humectant isadded to the melted oil or oils. The humectant is substantially fullydispersed in the one or more oils. Typically, high shear mixing is usedto disperse the humectant in the one or more oils; however, thehumectant can be dispersed in other ways. The temperature of the oil andhumectant mixture is maintained sufficiently high to prevent or minimizethe solidification and/or crystallization of the one or more oils untilthe humectant is dispersed in the one or more oils. In one embodiment,the temperature is maintained above about 140° F. If fruit solids,sweetener, lecithin, acidulant, starch, coloring agent, natural and/orartificial flavoring are to be added to the filling, such components areadded to and substantially fully dispersed in the one or more oils priorto the substantial solidification and/or crystallization of the one ormore oils. Typically, high shear mixing is used to disperse the fruitsolids, sweetener, lecithin, acidulant, starch, coloring agent, and/ornatural and/or artificial flavoring in the one or more oils; however,the fruit solids, sweetener, lecithin, acidulant, starch, coloringagent, and/or natural and/or artificial flavoring can be dispersed inother ways. As can be appreciated, the humectant, fruit solids,sweetener, lecithin, acidulant, starch, coloring agent, and/or naturaland/or artificial flavoring can be added together, separately, or invarious combinations when dispersing such components in the one or moreoils. Once the oil, humectant and fruit solids, sweetener, lecithin,acidulant, starch, coloring agent, and/or natural and/or artificialflavoring are mixed together, the temperature of the mixture is reducedto cause one or more of the oils to begin to crystallize. In oneembodiment, the temperature is maintained between about 80-160° F. Whena higher melting point oil is included in the filling, the highermelting point oil acts as a seeding agent for crystallization of one ormore of the other components in the mixture such as, but not limited to,one or more other oils in the mixture. During this initialcrystallization process, the mixture is typically slowly mixed tomaintain the dispersion of the components in the mixture. As the mixtureis further cooled, fat crystal growth in the mixture continues,resulting in the formation and increase in quantity of crystals in thefilling. The size of the crystals and resulting crystalline network arereduced by breaking or fracturing the crystals as the mixture is cooled.The crystal size and crystalline network can be reduced in a number ofdifferent manners. One particular method is by subjecting the mixture toa scraped surface heat exchanger or votator to simultaneously break thecrystals as the mixture is being cooled. In another embodiment, thetemperature of the final filling after being cooled is about 50-120° F.In one aspect of this embodiment, the crystals in the mixture arereduced until the temperature of the filling is about 60-115° F. Inanother aspect of this embodiment, the crystals in the mixture arereduced until the temperature of the filling is about 65-110° F. Instill another aspect of this embodiment, the crystals in the mixture arereduced until the temperature of the filling is about 70-100° F. In yetanother aspect of this embodiment, the crystals in the mixture arereduced until the temperature of the filling is about 77-95° F. In stillanother embodiment, the average crystal size of the one or more oils inthe filling prior to packaging or applying the filling in and/or onto afood product is less than about 30μ and that it is desireable that thecrystals be in the Beta Prime form. In one aspect of this embodiment,the average crystal size of the one or more oils is about 0.1-10μ. Inanother aspect of this embodiment, the average crystal size of the oneor more oils is about 0.5-8μ. In still another aspect of thisembodiment, the average crystal size of the one or more oils is about1-5μ. It has been found that by reducing the crystal size of the finalfilling and maintaining a reduced crystal size as the mixture is cooled,a processable final filling is formed which a) does not have a grainytaste or grainy texture, b) can be pumped, poured and/or extruded, c)has a low water activity, d) has desired organoleptic characteristicsthat are similar to fillings having significantly higher wateractivities, and e) retains its properties after being thawed ortempered. The process for manufacturing the final filling can beaccomplished by a batch or continuous process.

The principal object of the present invention is the provision of amethod and formulation, which method and formulation produce a fillinghaving a low water activity.

Another object of the present invention is the provision of a method andformulation which method and formulation is useful for producing afilling which has a high solid content, and has a low water activity.

Still another object of the present invention is the provision of amethod and formulation which method and formulation produces a fillinghaving desired organoleptic characteristics.

These and other objects and advantages will become apparent to thoseskilled in the art upon the reading and following of the descriptiontaken together with the accompanied drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference may now be made to the drawings, which illustrate variousembodiments that the invention may take in physical form and in certainparts and arrangements of parts wherein;

FIG. 1 is a perspective view of an edible oil crystal;

FIG. 1A is a perspective view of a fractured edible oil crystal as shownin FIG. 1;

FIG. 2 illustrates a globule of final filling in accordance with thepresent invention, wherein fractured edible oil crystals are dispersedwith various other components of the filling;

FIG. 3 is a side sectional view of a filled food product containingfinal filling;

FIG. 4 is a flow chart detailing a continuous process for themanufacturing of the filling;

FIG. 5 is a graphical illustration of the water activity of the fillingduring the continuous process manufacturing of the filling asillustrated in FIG. 4;

FIG. 6 is a perspective view of a scraped surface heat exchanger;

FIG. 7 is a graphical illustration of the crystal size of the one ormore edible oils in the filling as a function of the final processingtemperature of the filling;

FIG. 8 is a graphical illustration of the texture of the filling as afunction of the final processing temperature of the filling;

FIG. 9 is a flow chart detailing a batch process for the manufacturingof the filling; and

FIG. 10 is a graphical illustration of the water activity of the fillingduring the batch process manufacturing of the filling as illustrated inFIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein the showings are for the purposeof illustrating the preferred embodiments of the invention only and notfor the purpose of limiting the same, the present invention relatesgenerally to a filling which can be inserted onto or into a foodproduct. Such fillings include fruit fillings, marshmallow fillings,fruit flavored fillings, vegetable fillings, and the like. Typically,uses of the various types of fillings include insertion of the fillinginto a cracker, wafer, cookie, biscuit, pretzel, donut, muffin, cake,waffle, or the like. The filling is formulated to be stable so that thefilling can be packaged for later use, packaged and then frozen forlater use, inserted onto and/or into a food casing for immediate orlater consumption, and/or inserted onto and/or into a food casing whichis frozen and thawed and/or heated for later consumption. The filling isfreezer stable so that after it is thawed, the filling does notsubstantially degrade. The filling is also formulated to have thermaldurability. The filling is also formulated to have a low water activity.Heretofore, fillings such as fruit fillings, typically had wateractivities above about 0.6. Such high water activities for the fillingtypically resulted in the migration of the water from the filling into afood casing adjacent to or surrounding the filling, thereby resulting inthe food casing becoming soggy and/or otherwise becoming unacceptablefor consumption. The lower water activity of the filling of the presentinvention overcomes the problems associated with high water activitiesof past fillings.

The filling material generally comprises flavoring agents, edible oilsand humectant. The flavoring agent typically includes natural and/orartificial flavorings, such as fruit puree, fruit puree concentrate,fruit juice, fruit juice concentration, fruit concentrate, fruit flakes,fruit powder, vegetable puree, vegetable puree concentrate, vegetablejuice, vegetable juice concentrate, vegetable pieces, vegetableconcentrate, vegetable flakes, vegetable powder, artificial fruit,artificial fruit concentrate, artificial vegetables, artificialvegetable concentrate, dried fruit, dried vegetables, fruit extract,vegetable extract, cocoa, caramel, caramel powder, maple syrup, spices,chocolate, herbs, cheese, and/or flavored oils. Generally, the flavoragent that includes little or no water is added to the filling so as tominimize the water content of the final filling. As can be appreciated,the particular type of flavor agent and/or combination of flavoringagent used in the filling is dependent on the final use of the filling.The flavoring agent is added to the filling in a sufficient amount toprovide the desired flavor of the final filling. The edible oil andhumectant are added to provide flowability to the filling without theneed to add water to the filling. The filling also typically includes,but does not require, sweetener and/or lecithin. The sweetener providesthe desired sweetness to the final filling product. The lecithinfunctions as a emulsifier for the final filling. A general formulationfor the filling comprises:

Filling Material Percent By Weight Flavor Agent about 0.05-50% EdibleOil about 0.01-80% Humectant about 0.1-40% Sweetener about 1-80%Lecithin about 0.01-10%

A more specific formulation of the filling comprises:

Fruit  0-25 High Melting Point Oil 0-2 Low Melting Point Oil 10-55Humectant 10-30 Sweetener 30-45 Lecithin 0.1-2   Starch  1-40 Stabilizer 0-18 Acidulant 0.1-2   Flavoring Agent 0.1-2   Coloring Agent 0.01-2  

Various examples of the filling are set forth below:

EXAMPLE I

“Strawberry Filling” Weight Filling Material Percentage % SolidsStrawberry-Apple Flakes 5.24 4.98 Apple Powder 10 10 High Melting PointOil 1 1 Low Melting Point Oil 19 19 Humectant 20 19.9 Powdered Sweetener23.56 23.56 Liquid Sweetener 17.3 13.32 Lecithin 0.2 0.198 InstantModified Starch 2 1.9 Flavored Strawberry 1 0.57 Malic Acid 0.6 0.6Tater Red 0.1 0.1

EXAMPLE II

“Marshmallow Filling” Weight Filling Material Percentage % SolidsMarshmallow 0.16 0.16 Low Melting Point Oil 20 20 Humectant 20 19.9Powdered Sweetener 23.69 23.69 Liquid Sweetener 16.4 12.63 Lecithin 0.50.49 Instant Modified Starch 2 1.9 Instant Natural Starch 1 0.95Stabilizer 15 14.8 Titanium Dioxide 1 1 Salt 0.25 0.25

EXAMPLE III

“Orange Filling” Weight Filling Material Percentage % Solids OrangeFlakes 5 4.8 Apple Powder 10 10 Low Melting Point Oil 20 20 Humectant 2019.9 Powdered Sweetener 22.98 22.98 Liquid Sweetener 17.3 13.32 Lecithin0.5 0.49 Instant Modified Starch 2 1.9 Instant Natural Starch 1 0.95Citric Acid 0.6 0.6 Natural and Artificial 0.5 0.15 Orange FlavoringYellow Coloring 0.025 0 Titanium Dioxide 0.1 0.1

EXAMPLE IV

“Blueberry Filling” Weight Filling Material Percentage % SolidsBlueberry Grape-Apple Flakes 5.24 5.08 Apple Powder 10 10 Low MeltingPoint Oil 20 20 Humectant 20 19.9 Powdered Fructose 22.16 22.16 LiquidSweetener 17.3 13.32 Lecithin 0.5 0.49 Instant Modified Starch 2 1.9Instant Natural Starch 1 0.95 Blueberry 1 0.35 Malic Acid 0.6 0.6 FD&CPurple Shade 0.1 0.1 FD&C Blue 2 0.1 0.1

EXAMPLE V

“Grape Filling” Weight Filling Material Percentage % SolidsGrape-Concord Dried Flakes 5.24 5.08 Apple Powder 10 10 Low MeltingPoint Oil 20 20 Humectant 20 19.9 Powdered Sweetener 22.33 22.33 LiquidSweetener 17.3 13.32 Lecithin 0.5 0.49 Instant Modified Starch 2 1.9Instant Natural Starch 1 0.95 Grape Wonf 1 0.34 Malic Acid 0.6 0.6 ColorWJ Blueberry 0.03 0.03

EXAMPLE VI

“Lemon Filling” Weight Filling Material Percentage % Solids Freeze DriedLemon Powder 1 0.96 Fancy Orange Flakes 4 3.84 Apple Powder 10 10 LowMelting Point Oil 20 20 Humectant 20 19.9 Powdered Sweetener 22.43 22.43Liquid Sweetener 17.3 13.32 Lecithin 0.5 0.49 Instant Modified Starch 21.9 Instant Natural Starch 1 0.95 Citric Acid 0.6 0.6 FD&C Yellow 5 Alum0.15 0.15 FD&C Yellow Coloring 0.02 0 Titanium Dioxide 1 1

EXAMPLE VII

“Apple/Cinnamon Filling” Weight Filling Material Percentage % SolidsApple Powder 15.25 15.25 Low Melting Point Oil 20 20 Humectant 20 19.9Powdered Sweetener 23.40 23.40 Liquid Sweetener 17.3 13.32 Lecithin 0.50.49 Instant Modified Starch 2 1.9 Instant Natural Starch 1 0.95 GroundCinnamon 0.14 0.14 Malic Acid 0.4 0.4 Caramel Color 0.01 0.01

In the seven examples illustrated above, the percent solids representthe non-water content of the filling. All the above examples have awater content of less than about 6 weight percent and a water activityof less than about 0.5.

The process for manufacturing the novel filling is illustrated in FIGS.4 and 9. FIG. 4 illustrates a continuous process for manufacturing thefilling. FIG. 9 illustrates a batch process for manufacturing thefilling. In both processes, a fruit filling is illustrated; however,non-fruit fillings can be manufactured by both these processes.

Referring now to FIG. 4, the principal process steps are numbered. Thesenumbered process steps correspond to the graphical illustration of thewater activity of the filling during manufacture as illustrated in FIG.5. As shown in FIG. 4, the first process step involves the melting ofthe one or more edible oils. Step-two illustrates the filling includingtwo edible oils or shortenings, one shortening having a melting point of95° F., referred to as a low melting point oil, and the other shorteninghas a melting point of 140° F., referred to as a high melting point oil.The two shortenings are heated to a temperature of about 150° F. andmixed together so as to fully melt the two shortenings. At this point ofthe process, the filling has essentially no moisture and theoreticallyno A_(w). Therefore, as shown in FIG. 5, the water activity when the twoshortenings are melted together is close to 0.

In step two of the process, liquid fructose is added to the meltedshortening and dispersed therein by high shear mixing. The addition ofliquid fructose adds fluidity to the mixture. The liquid fructoseincludes some water in the fructose, typically an 80/20 fructose syrup.As shown in FIG. 5, the addition of liquid fructose to the meltedshortening increases the water activity of the filling to about 0.60.

In step three of the process, lecithin, glycerin, dried fructose, acid,coloring agents, and flavoring agents are added to the shortening andliquid fructose mixture. At this step, the water content of the fillingis very low as indicated by the overall solids content of 94-96%. Asshown in FIG. 5, in step three of the process, the water activity of themixture decreases to about 0.30. These components are mixed in highshear conditions to disperse the components in the mixture.

In step four of the process, the mixture is held in a surge tank andmixed. The temperature of the mixture is held to about 110-160° F. Thecooling of the mixture below the melting point of the high melting pointoil results in the high melting point oil to begin to crystallize. FIG.1 illustrates a typical shortening crystal 20 which forms during stepfour of the process. Once the high melting point oil begins tocrystallize, these crystals act as seeding agents for crystallization ofother components in the filling such as, but not limited to, the lowmelting point oil and the sweetener. As illustrated in FIG. 5, the wateractivity of the filling does not increase during the mixing of thecomponents.

In step five of the process, the mixture is directed through a flowmeter and into a blender as designated by step six. The mixture isblended with fruit solids and starch in step 6. As illustrated in FIG.5, the water activity-remains relatively-constant at about 0.30 when thefruit solids and starch are added to the mixture during the blendingstep. The fruit solids and starch are typically in a powdered or drystate, thus have a low water content so as not to substantially increasethe water activity of the filling. The fruit solids and starch are fedinto a blender in step six of the process and substantially fullydispersed with the shortening-sweetener mixture. Various types ofblenders can be used to blend the components together. Such blendersinclude, but are not limited to, a triblender or a static blender.

Once the components are blended together, the mixed components aredirected to a scraped surface heat exchanger to further cool the fillingcomponents. FIG. 6 illustrates a standard scraped surface heat exchanger80. Scraped surface heat exchanger 80 includes a container 82, whereinthe filling components are directed therein. While the fillingcomponents F are maintained in the container 82 of the scraped surfaceheat exchanger, a rotating arm 84 rotates a scraper blade 86 along theinner surface of container 82. Scraper blade 86 causes the crystals thathave formed, or are in the process of forming, in filler F to befractured. FIG. 1A illustrates the fracturing of a high melting pointoil crystal in the scraped surface heat exchanger. Fractured crystals 20a continually grow and become refractured as the mixture is cooled andas scraper blade 86 rotates along the interior surface of container 82.A cooling jacket 88 surrounds the outer surface of container 82 allowinga cooling fluid, such as water, cooling gases, and/or cooling liquids,to pass therethrough. The flow of the cooling fluid through the coolingjacket 88 causes cooling of container 82, which in turn causes thefilling components within container 82 to decrease in temperature. Thefilling components are maintained in the scraped surface heat exchangeruntil the temperature of the filling component is between about 40-110°F., and typically about 40-100° F., and more typically about 40-90° F.The final crystal size of the shortening in final filling F after thefilling is cooled and passed through the scraped surface heat exchanger,it is about 1-30μ, and typically about 1-10μ and more typically about1-5μ. FIG. 2 illustrates final filling F which includes fracturedshortening 20 a dispersed with the fruit solids 30, starch 40, glycerin50, humectant 60, and fructose 70. The final filling has a wateractivity of less than about 0.4 and a water content of less than about5.5 weight percent. This water activity is significantly less than the0.7 water activity and 25 weight percent water of standard fruitfillings. Although the fruit filling has significantly less water and asignificantly lower water activity of standard fruit fillings, thetexture, taste, post processability, and other organolepticcharacteristics are similar to those of standard fruit fillings.

Referring now to FIG. 9, a batch process for manufacturing the fillingis illustrated. The principal process steps are numbered. These numberedprocess steps correspond to the graphical illustration of the wateractivity of the filling during manufacture as illustrated in FIG. 9. Inthe batch process, the high melting point shortening and low meltingpoint shortening are heated during step 1 until fully melted. The wateractivity of the oils is zero or very close to zero. After theshortenings are melted, glycerin, fruit solids, lecithin, and/or colorare mixed with the shortening under high shear mixing conditions in step2 so as to disperse these components into the melted shortening. Thewater activity of the mixture increases to about 0.153 during this step.In step 3, powdered fructose, acid and flavoring are then mixed with theother components of the filling under high shear conditions tosubstantially fully disperse the components of the mixture. The wateractivity of the mixture slightly increases to about 0.157. Finally,liquid fructose and starch are added to the mixture under high shearconditions in step 4. The liquid fructose and starch are added last todelay starch hydration and premature viscosity build-up of the fillingcomponents. The water activity of the mixture increases to about 0.3during step 4. The mixture is then mixed and held in a surge tank toabout 110-160° F. During the cooling process, the high melting point oilbegins to crystallize. After the mixture has been held in the surge tankfor a sufficient amount of time and tempered to the desired temperature,the mixture is transferred to a scraped surface heat exchanger, whereinthe mixture is cooled to a temperature between about 40-110° F. Once thedesired crystal size and temperature of the filling is obtained in thescraped surface heat exchanger, the filling is transferred to packagingand stored for later use. Typically, the filling, after being packaged,is stored at ambient room temperature. The water activity of the mixtureremains substantially constant during steps 5 and 6. As illustrated inFIGS. 5 and 10, the water activity profile of the mixture is differentin a batch or continuous process. However, in both processes, the finalwater activity of the filling is about 0.3.

FIGS. 7 and 8 graphically illustrate the relationship of the crystalsize and texture of the filling as a function of the temperature of thefilling when it is removed from the scraped surface heat exchanger. Asshown in FIG. 7, when the filling is removed from the scraped surfaceheat exchanger at about 110°-120° F., the crystal size of the finalfilling will be relatively large. When the filling is removed from thescraped surface heat exchanger at a temperature of about 77-90° F., thecrystal size of the shortening is substantially smaller. As shown inFIG. 8, a correlation exists between smaller crystal sizes and softerfilling textures. Filling having a smaller crystal size and which isremoved from the scraped surface heat exchanger at a lower temperaturehas a smoother texture. Filling having a larger crystal size and whichis removed from the scraped surface heat exchanger at a highertemperature has a harder texture. It is believed that when the fillingis removed from the scraped surface heat exchanger at temperatures above110° F., substantial crystal growth continues as the filling cools to orbelow ambient temperature (70°-77° F.). This continued crystal growthresults in larger crystals in the final filling and increased texturalhardness of the filling. However, it is believed that when the crystalsare continually fractured as the filling temperature falls below 110°F., the growth rate of the crystals is significantly less after thefilling is removed from the scraped surface heat exchanger and allowedto further cool to or below ambient temperature. Cooling the filling tolow temperatures is also believed to help stabilize the final filling.As a result, the final filling has smaller crystals and a softertexture. The use of the high melting point oil as a seed forcrystallization causes crystallization of the filler components athigher temperatures, thereby resulting in a more stabilized productafter the crystals are fractured which in turn allows the filling to bepackaged at higher temperatures and maintain a soft texture withincreased stability. It has also been found that when the filling isreheated and cooled, the texture of the filling is not significantlyaltered. Furthermore, when the filling is cooled to lower temperaturesin the scraped surface heat exchanger, significantly less shorteningseparation from the filling occurs during packaging, storage andreheating, thereby resulting in a more stable filling. The soft texturedfilling has desired flowability characteristic such that the filling canbe easily pumped or extruded for packaging for future use, or beinserted on or into a final food product.

Referring now to FIG. 3, a food product is illustrated, wherein fillingF is inserted between two layers of food casing 90, 100. Food casings90, 100 can constitute a wide variety of food casings such as layers ofcrackers, cookies, crunchy granola bars, crusts, and the like. As shownin FIG. 3, the water activity of the filling is less than the wateractivity of food casing layers 90, 100 thus resulting in moisture fromfilling F not migrating to either food layer 90 or 100. As a result, thelow water activity filling F does not cause the boundary between fillingF and the food layers to become soggy or to cause degradation of thefood casings.

The invention has been described with reference to a preferredembodiment and alternatives thereof. It is believed that manymodifications and alterations to the embodiments disclosed will readilysuggest itself to the those skilled in the art upon reading andunderstanding the detailed description of the invention. It is intendedto include all such modifications and alterations insofar as they comewithin the scope of the present invention.

We claim:
 1. A method of preparing a low water activity fruit flavoredfilling comprising: a) substantially completely melting at least aportion of a low melting point oil and a high melting point oil, saidlow melting point oil having an average melting point temperature of atleast about 10° F. lower than an average melting point temperature ofsaid high melting point oil; b) at least partially blending togethersaid low melting point oil and said high melting point oil to form amixture of oils; c) at least partially blending a flavoring agent withsaid blend of oils to form a blend of flavoring agent and oils, saidflavoring agent including a fruit, a fruit flavor, and mixtures thereof;d) at least partially cooling said blend of flavoring agent and oils toa temperature below the average melting point of said low melting pointoil; and, e) at least partially breaking-up fat crystals forming in saidblend of flavoring agent and oils as said blend of flavoring agent andoils is cooled, said fruit flavored filling including about 0.05-40% byweight flavoring agent, at least about 0.01% by weight of said highmelting point oil, up to about 60% by weight of said low melting pointoil, about 0.1-40% by weight humectant, and an A_(w) of less than about0.8.
 2. The method as defined in claim 1, wherein said low melting pointoil has an average melting point temperature of up to about 120° F. 3.The method as defined in claim 1, wherein said high melting point oilhas an average melting point temperature of over 110° F.
 4. The methodas defined in claim 1, wherein said fruit flavored filling includesabout 0.1-30% by weight fruit.
 5. The method as defined in claim 1,including the step of adding and at least partially blending a saidhumectant with said oils prior to adding said flavoring agent.
 6. Themethod as defined in claim 1, including the step of adding and at leastpartially blending lecithin with said oils prior to adding saidflavoring agent.
 7. The method as defined in claim 6, wherein saidlecithin is about 0.01-5% by weight of said fruit flavored filling. 8.The method as defined in claim 1, including the step of adding and atleast partially blending a sweetener with said oils prior to adding saidflavoring agent.
 9. The method as defined in claim 1, including the stepof adding and at least partially blending a water swelling starch withsaid oils after said oils are at least partially blended together. 10.The method as defined in claim 9, wherein said water swelling starch isabout 0.01-15% by weight of said fruit flavored filling.
 11. The methodas defined in claim 1, including the step of adding and at leastpartially blending an acidulant with said oils prior to adding saidflavoring agent.
 12. The method as defined in claim 11, wherein saidacidulant is about 0.05-5% by weight of said fruit flavored filling. 13.The method as defined in claim 1, wherein said blend of flavoring agentand oils is at least partially inserted on or filled in a dough casing.14. The method as defined in claim 13, wherein said blend of flavoringagent and oils has a water activity that is less than or equal to awater activity of said dough casing.
 15. The method as defined in claim13, wherein said blend of flavoring agent and oils comprises: a) about0.05-40% by weight of said flavoring agent; b) about 0.01-10% by weightof said high melting point oil; c) about 15-25% by weight of said lowmelting point oil; d) about 10-25% by weight humectant; e) about 0.1-5%by weight starch; f) about 10-50% by weight sweetener; g) about 0.01-5%by weight lecithin; h) about 0-1.5% by weight acidulant; i) about 0-2%by weight coloring agent; and j) an A_(w) of less than about 0.6. 16.The method as defined in claim 1, wherein said blend of flavoring agentand oils comprises: a) about 0.05-40% by weight of said flavoring agent;b) about 0.01-10% by weight of said high melting point oil; c) about15-25% by weight of said low melting point oil; d) about 10-25% byweight humectant; e) about 0.1-5% by weight starch; f) about 10-50% byweight sweetener; g) about 0.01-5% by weight lecithin; h) about 0-1.5%by weight acidulant; i) about 0-2% by weight coloring agent; and j) anA_(w) of less than about 0.6.
 17. The method as defined in claim 16,wherein said blend of flavoring agent and oils comprises: a) about 5-20%by weight of said flavoring agent; b) about 0.5-1.5% by weight of saidhigh melting point oil; c) about 15-22% by weight of said low meltingpoint oil; d) about 15-25% by weight of said humectant; e) about 1-4% byweight of said starch; f) about 30-45% by weight of said sweetener; g)about 0.1-1% by weight of said lecithin; h) about 0-1.5% by weight ofsaid acidulant; i) about 0-2% by weight of said coloring agent; and j)an A_(w) of less than about 0.3.
 18. A method of preparing a low wateractivity flavored filling comprising: a) substantially completelymelting a low melting point oil and a high melting point oil, said lowmelting point oil having an average melting point temperature of atleast about 10° F. lower than an average melting point temperature ofsaid high melting point oil, said average melting point temperature ofsaid low melting point oil up to about 120° F., said average meltingpoint temperature of said high melting point oil over 110° F., said lowmelting point oil having a higher weight percentage than said highmelting point oil; b) at least partially blending together said lowmelting point oil and said high melting point oil to form a blend ofoils; c) at least partially blending a flavoring agent with said blendof oils; and, d) at least partially cooling said blend of flavoringagent and oils to a temperature below the average melting pointtemperature of said low melting point oil, said flavored fillingincluding about 0.05-40% by weight flavoring agent, at least about 0.01%by weight of said high melting point oil, up to about 60% by weight ofsaid low melting point oil, about 0.1-40% by weight humectant, and anA_(w) of less than about 0.8.
 19. The method as defined in claim 18,including the step of at least partially blending said humectant withsaid blend of oils prior to adding said flavoring agent.
 20. The methodas defined in claim 19, including the step of at least partiallyblending said humectant with said blend of oils prior to at leastpartially cooling said blend of flavoring agent and oils to atemperature below the average melting point temperature of said lowmelting point oil.
 21. The method as defined in claim 20, including thestep of at least partially blending an emulsifier with said blend ofoils prior to adding said flavoring agent.
 22. The method as defined inclaim 21, including the step of at least partially blending anemulsifier with said blend of oils prior to said step of at leastpartially cooling said blend of flavoring agent and oils.
 23. The methodas defined in claim 22, wherein said flavored filling includes about0.01-5% by weight emulsifier.
 24. The method as defined in claim 21,including the step of adding and at least partially blending a sweetenerwith said blend of oils prior to adding said flavoring agent.
 25. Themethod as defined in claim 24, including the step of at least partiallyblending a sweetener with said blend of oils prior to said step of atleast partially cooling said blend of flavoring agent and oils.
 26. Themethod as defined in claim 25, wherein said flavored filling includesabout 10-50% by weight sweetener.
 27. The method as defined in claim 24,including the step of adding and at least partially blending a starchwith said blend of oils prior to adding said flavoring agent.
 28. Themethod as defined in claim 27, including the step of adding and at leastpartially blending a starch with said blend of oils prior to said stepof at least partially cooling said blend of flavoring agent and oils.29. The method as defined in claim 28, wherein said flavored fillingincludes about 0.01-15% by weight starch.
 30. The method as defined inclaim 27, including the step of at least partially high shear blendingat least one component in said blend of flavoring agent and oils priorto said step of at least partially cooling said blend of flavoring agentand oils.
 31. The method as defined in claim 30, including the step ofat least partially breaking-up crystals forming in said blend offlavoring agent and oils as said blend of flavoring agent and oils iscooled.
 32. The method as defined in claim 31, wherein said step of atleast partially breaking-up crystals includes breaking-up crystals untilsaid blend of flavoring agent and oils is cooled to about 60-110° F. andthe average crystal size of said crystals is about 0.1-30μ.
 33. Themethod as defined in claim 32, wherein said flavored filling comprisingabout 1-40% by weight flavoring agent.
 34. The method as defined inclaim 33, wherein said flavored filling includes about 0.1-30% by weightfruit.
 35. The method as defined in claim 33, wherein said flavoredfilling comprising up to about 50% by weight of a low melting point oil.36. The method as defined in claim 35, wherein said weight percentage ofsaid low melting point oil is at least about twice the weight percentageof said high melting point oil.
 37. The method as defined in claim 36,wherein said weight percent of said low melting point oil is up to about50, and said weight percent of said high melting point oil is about0.01-30.
 38. The method as defined in claim 37, wherein said flavoredfilling includes: a) about 0.05-40% by weight flavoring agent, saidflavoring agent including up to 100% by weight fruit; b) about 0.01-10%by weight of high melting point oil; c) about 15-25% by weight of lowmelting point oil; d) about 10-25% by weight humectant, e) about 0.1-5%by weight starch; f) about 10-50% by weight sweetener; g) about 0.01-5%by weight lecithin; and, h) an A_(w) of less than about 0.6.
 39. Themethod as defined in claim 38, including the step of at least partiallyinserting said flavored filling on or in a food casing.
 40. The methodas defined in claim 39, wherein said food casing has a water activity,said flavored filling having an average water activity that is less thanor equal to the water activity of said food casing.
 41. The method asdefined in claim 40, including the step of inserting said flavoredfilling in a package and then storing said flavored filling at atemperature up to ambient room temperature for later use.
 42. The methodas defined in claim 20, wherein said flavored filling includes about1-40% by weight humectant.
 43. The method as defined in claim 18,including the step of at least partially blending said humectant withsaid blend of oils prior to said step of at least partially cooling saidblend of flavoring agent and oils.
 44. The method as defined in claim18, wherein said flavored filling includes about 1-40% by weighthumectant.
 45. The method as defined in claim 18, wherein said humectantincludes a compound selected from the group consisting of glycerine,1,3-butyl glycol, mannitol, sorbitol, fructose, propylene glycol, andmixtures thereof.
 46. The method as defined in claim 45, wherein saidhumectant includes glycerin, propylene glycol, and mixtures thereof. 47.The method as defined in claim 18, including the step of at leastpartially blending an emulsifier with said blend of oils prior to addingsaid flavoring agent.
 48. The method as defined in claim 47, includingthe step of at least partially blending an emulsifier with said blend ofoils prior to said step of at least partially cooling said blend offlavoring agent and oils.
 49. The method as defined in claim 47, whereinsaid flavored filling includes about 0.01-5% by weight emulsifier. 50.The method as defined in claim 18, including the step of at leastpartially blending an emulsifier with said blend of oils prior to saidstep of at least partially cooling said blend of flavoring agent andoils.
 51. The method as defined in claim 18, wherein said flavoredfilling includes about 0.01-5% by weight emulsifier.
 52. The method asdefined in claim 18, including the step of adding and at least partiallyblending a sweetener with said blend of oils prior to adding saidflavoring agent.
 53. The method as defined in claim 52, including thestep of at least partially blending a sweetener with said blend of oilsprior to said step of at least partially cooling said blend of flavoringagent and oils.
 54. The method as defined in claim 52, wherein saidflavored filling includes about 10-50% by weight sweetener.
 55. Themethod as defined in claim 18, including the step of at least partiallyblending a sweetener with said blend of oils prior to said step of atleast partially cooling said blend of flavoring agent and oils.
 56. Themethod as defined in claim 18, wherein said flavored filling includesabout 10-50% by weight sweetener.
 57. The method as defined in claim 18,including the step of adding and at least partially blending a starchwith said blend of oils prior to adding said flavoring agent.
 58. Themethod as defined in claim 57, including the step of adding and at leastpartially blending a starch with said blend of oils prior to said stepof at least partially cooling said blend of flavoring agent and oils.59. The method as defined in claim 57, wherein said flavored fillingincludes about 0.01-15% by weight starch.
 60. The method as defined inclaim 18, including the step of adding and at least partially blending astarch with said blend of oils prior to said step of at least partiallycooling said blend of flavoring agent and oils.
 61. The method asdefined in claim 18 wherein said flavored filling includes about0.01-15% by weight starch.
 62. The method as defined in claim 18,including the step of at least partially high shear blending at leastone component in said blend of flavoring agent and oils prior to saidstep of at least partially cooling said blend of flavoring agent andoils.
 63. The method as defined in claim 18, including the step of atleast partially breaking-up crystals forming in said blend of flavoringagent and oils as said blend of flavoring agent and oils is cooled. 64.The method as defined in claim 63, wherein said step of at leastpartially breaking-up crystals includes breaking-up crystals until saidblend of flavoring agent and oils is cooled to about 60-110° F. and theaverage crystal size of said crystals is about 0.1-30μ.
 65. The methodas defined in claim 18, wherein said flavored filling comprising about1-40% by weight flavoring agent.
 66. The method as defined in claim 18,wherein said flavored filling includes about 0.1-30% by weight fruit.67. The method as defined in claim 66, wherein said fruit includes fruitpuree, fruit puree concentrate, fruit juice, fruit juice concentrate,fruit pieces, fruit concentrate, fruit flakes, fruit powder, andmixtures thereof.
 68. The method as defined in claim 18, wherein saidflavored filling comprising up to about 50% by weight of a low meltingpoint oil.
 69. The method as defined in claim 18, wherein said weightpercentage of said low melting point oil is at least about twice theweight percentage of said high melting point oil.
 70. The method asdefined in claim 69, wherein said weight percent of said low meltingpoint oil is up to about 50, and said weight percent of said highmelting point oil is about 0.01-30.
 71. The method as defined in claim70, wherein said weight percent of said low melting point oil is about5-25, and said weight percent of said high melting point oil is about0.01-20.
 72. The method as defined in claim 18, wherein said weightpercent of said low melting point oil is up to about 50, and said weightpercent of said high melting point oil is about 0.01-30.
 73. The methodas defined in claim 72, wherein said weight percent of said low meltingpoint oil is about 5-25, and said weight percent of said high meltingpoint oil is about 0.01-20.
 74. The method as defined in claim 18,wherein said average melting point temperature of said low melting pointoil is about 60-110° F., and said average melting point temperature ofsaid high melting point oil is about 130-200° F.
 75. The method asdefined in claim 18, wherein said water activity of said flavoredfilling is less than about 0.7.
 76. The method as defined in claim 75,wherein said water activity of said flavored filling is less than about0.5.
 77. The method as defined in claim 18, wherein said flavoredfilling includes less than about 10% by weight water.
 78. The method asdefined in claim 77, wherein said flavored filling includes less thanabout 5.5% by weight water.
 79. The method as defined in claim 18,wherein said flavored filling includes: a) about 0.05-40% by weightflavor flavoring agent, said flavoring agent including up to 100% byweight fruit; b) about 0.01-10% by weight of high melting point oil; c)about 15-25% by weight of low melting point oil; d) about 10-25% byweight humectant; e) about 0.1-5% by weight starch; f) about 10-50% byweight sweetener; g) about 0.01-5% by weight lecithin; and, h) an A_(w)of less than about 0.6.
 80. The method as defined in claim 18, includingthe step of at least partially inserting said flavored filling on or ina food casing.
 81. The method as defined in claim 80, wherein said foodcasing has a water activity, said flavored filling having an averagewater activity that is less than or equal to the water activity of saidfood casing.
 82. The method as defined in claim 18, including the stepof inserting said flavored filling in a package and then storing saidflavored filling at a temperature up to ambient room temperature forlater use.
 83. The method as defined in claim 18, wherein said flavoringagent includes natural flavorings, artificial flavorings and mixturesthereof.
 84. The method as defined in claim 18, wherein said flavoringagent includes fruit puree, fruit puree concentrate, fruit juice, fruitjuice concentrate, fruit pieces, fruit concentrate, fruit flakes, fruitpowder, vegetable puree, vegetable puree concentrate, vegetable juice,vegetable juice concentrate, vegetable pieces, vegetable concentrate,vegetable flakes, vegetable powder, artificial fruit, artificial fruitconcentrate, artificial vegetable, artificial vegetable concentrate,dried fruit, dried vegetable, fruit extract, vegetable extract, cocoa,caramel, caramel powder, maple syrup, spices, chocolate herbs, flavoredoils, and mixtures thereof.